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Honestly, it is a big job. I am going to provide directions for taking the transfer case apart and directions for removal. With that, you can determine if it is something you want to do. Note that there are two different types of transfer cases on this vehicle. One is for AWD and the other is for automatic 4wd. You will need to let me know which one you have so I can confirm the information I provide. Regardless, is it basically the same for either.
The directions are for the automatic 4wd. If you have the other, let me know. Also, the attached pictures correlate with the directions. I only provided the directions to actually separate the two casings.
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2002 Ford Truck Explorer 4WD V6-4.0L VIN E
Vehicle Transmission and Drivetrain Transfer Case Service and Repair Procedures Transfer Case-Automatic Shift Disassembly
1. Remove the transfer case.
2. Remove the dampener.
3. Remove the heat shield.
4. WARNING: Make sure the Holding Fixture lock pin is secure.
Using the special tool, secure the transfer case to the bench.
5. Index-mark the rear output flange and the rear output shaft.
6. Using the special tool to hold the rear output flange, remove the nut.
7. Remove the rear output flange and the output shaft yoke washer.
8. Remove the oil seal.
9. Using the special tools, remove the oil seal.
10. Remove the coil wire pin from the electrical connector.
1 Remove the connector interlock.
2 Remove the coil wire pin.
1 Use electrical connector pin extractor tool.
11. Remove the front and rear output shaft speed sensor bolts. Carefully remove the sensors from the transfer case.
12. Remove the four bolts and the transfer case shift motor.
13. NOTE: Inspect the tone wheel teeth for damage.
If necessary, remove and discard the tone wheel.
14. Remove the 17 bolts.
15. Remove the clutch coil assembly nuts.
16. Separate the transfer case halves at the transfer case pry bosses.
Here are the directions for removing the transfer case.
Transfer Case -Automatic Transmission
1. Remove the upper radiator cover.
2. Carry out the following on the RH side of the upper fan shroud.
1 Disconnect the air conditioning line from the bracket, if equipped.
2 Remove the screw, if equipped.
3 Remove the bolt.
3. Carry out the following on the LH side of the upper fan shroud.
1 Remove the screw, if equipped.
2 Remove the bolt.
3 Remove the upper fan shroud.
4. With the vehicle in neutral, raise and support the vehicle.
5. Remove the four bolts and the skid plate, if equipped.
6. Drain the fluid if the transfer case is to be disassembled.
7. NOTE: Index-mark the driveshaft yoke to the rear axle flange and to the transfer case flange.
Remove the rear driveshaft.
8. NOTE: Index-mark the driveshaft yoke to the transfer case flange and to the front axle flange.
Remove the front driveshaft.
9. Disconnect the motor electrical connector, if equipped.
10. Disconnect the vent hose.
11. Remove the RH and LH heat shield-to-crossmember bolts.
12. Remove the two nuts and the RH crossmember cover, then remove the four crossmember bolts.
13. Remove the four LH crossmember bolts.
14. Position a suitable transmission jack to the transfer case. Securely strap the transfer case to the jack.
15. Remove the transmission mount nuts, then remove the crossmember.
It may be necessary to pry the crossmember from the vehicle.
16. Remove the transmission mount.
17. Lower the transmission jack down just enough to access the upper transfer case to transmission bolts, including the bolt retaining the fuel line bracket. Position the bracket out of the way.
18. Position a suitable jack under the transmission.
19. Remove the remaining transfer case to transmission bolts. Separate the transfer case from the transmission.
20. Remove the transfer case from the vehicle.
Move the transfer case rearward until the transfer case clears the output shaft. Lower and at the same time slightly tilt the rear of the transfer case downward.
21. Remove and discard the transfer case to transmission gasket. Clean the transfer case and transmission mating surfaces.
I hope this helps. Let me know the specifics if you decide to do the work.
Images (Click to enlarge)
Sunday, April 21st, 2019 AT 9:25 PM